Fluid-filled pad with voids

ABSTRACT

Aspects herein are directed to a fluid-filled pad for a protective garment. The fluid-filled pad includes two or more elongate voids that extend entirely through the fluid-filled pad. The elongate voids are positioned inward from an exterior edge of a first surface of the fluid-filled pad, and one elongate void extends from another elongate at an angle that is less than 180 degrees. Other aspects are directed to a protective garment system in which the fluid-filled pad is positioned between a first textile layer and a second textile layer of a garment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application, having attorney docket number 373388/200061US02 and titled “Fluid-Filled Pad with Voids,” claims the benefit of priority of U.S. Prov. App. No. 63/112,911, filed Nov. 12, 2020, and titled “Fluid-Filled Pad with Voids.” The entirety of the aforementioned application is incorporated by reference herein.

TECHNICAL FIELD

Aspects herein are directed to a fluid-filled pad for a protective garment with voids that extend entirely through the fluid-filled pad to provide articulation and ventilation.

BACKGROUND

Traditional fluid-filled pads provide articulation by being filled to less than optimal pressure and/or by utilizing multiple, individual bladders that are interconnected by bridges of thin material. In either instance, protection and ventilation properties are reduced as a side effect of articulation. As such, traditional fluid-filled pads fail to provide articulation, while maintaining ventilation and protective features.

SUMMARY

The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting.

Clause 1. A fluid-filled pad for a protective garment, the fluid-filled pad comprising: a first surface having an exterior edge; a second surface positioned opposite the first surface, the second surface affixed to the first surface along the exterior edge; a fluid-filled portion positioned between the first surface and the second surface; a first elongate void positioned inwardly from the exterior edge of the first surface, the first elongate void extending through the first surface, the fluid-filled portion, and the second surface; and a second elongate void positioned inwardly from the exterior edge of the first surface, the second elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the second elongate void extends from the first elongate void at an angle that is less than 180 degrees.

Clause 2. The fluid-filled pad of clause 1, wherein each of the first elongate void and the second elongate void extend linearly.

Clause 3. The fluid-filled pad according to any of clauses 1 through 2, wherein the first surface is affixed to the second surface along a periphery of the first elongate void and the second elongate void.

Clause 4. The fluid-filled pad according to any of clauses 1 through 3 further comprising: a first textile layer positioned adjacent to the first surface of the fluid-filled pad; and a second textile layer positioned adjacent to the second surface of the fluid-filled pad, wherein the first textile layer is affixed to the second textile layer at one or more of the first elongate void and the second elongate void.

Clause 5. The fluid-filled pad according to any of clauses 1 through 4 further comprising a third elongate void positioned inwardly from the exterior edge of the first surface, the third elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the third elongate void is spaced apart from the first elongate void and the second elongate void.

Clause 6. The fluid-filled pad according to any of clauses 1 through 5 further comprising: a third elongate void positioned inwardly from the exterior edge of the first surface, the third elongate void extending through the first surface, the fluid-filled portion, and the second surface; and a fourth elongate void positioned inwardly from the exterior edge of the first surface, the fourth elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the fourth elongate void extends from the third elongate void at an angle that is less than 180 degrees.

Clause 7. The fluid-filled pad according to clause 6 further comprising a fifth elongate void positioned inwardly from the exterior edge of the first surface, the fifth elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the fifth elongate void is spaced apart from the first elongate void, the second elongate void, the third elongate void, and the fourth elongate void.

Clause 8. A protective garment system comprising: a garment having a first textile layer and a second textile layer; and a fluid-filled pad positioned between the first textile layer and the second textile layer, the fluid-filled pad comprising: a first surface having an exterior edge, a second surface positioned opposite the first surface, the second surface affixed to the first surface along the exterior edge, a fluid-filled portion positioned between the first surface and the second surface, a first elongate void positioned inwardly from the exterior edge of the first surface, the first elongate void extending through the first surface, the second surface, and the fluid-filled portion, and a second elongate void positioned inwardly from the exterior edge of the first surface, the second elongate void extending through the first surface, the second surface, and the fluid-filled portion, wherein the second elongate void extends from the first elongate void at an angle that is less than 180 degrees.

Clause 9. The protective garment system of clause 8, wherein the first textile layer is affixed to the second textile layer around the exterior edge.

Clause 10. The protective garment system according to any of clauses 8 through 9, wherein the first textile layer is affixed to the second textile layer at the first elongate void and at the second elongate void.

Clause 11. The protective garment system according to any of clauses 8 through 10 further comprising: a third elongate void positioned inwardly from the exterior edge of the first surface, the third elongate void extending through the first surface, the fluid-filled portion, and the second surface; and a fourth elongate void positioned inwardly from the exterior edge of the first surface, the fourth elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the fourth elongate void extends from the third elongate void at an angle that is less than 180 degrees.

Clause 12. The protective garment system according to clause 11, wherein the first textile layer is affixed to the second textile layer around the exterior edge, at the first elongate void, at the second elongate void, at the third elongate void, and at the fourth elongate void.

Clause 13. The protective garment system according to any of clauses 8 through 12, wherein the first textile layer forms the garment.

Clause 14. The protective garment system according to any of clauses 8 through 13, wherein the second textile layer forms a patch on an interior of the garment that extends overtop the fluid-filled pad.

Clause 15. The protective garment system according to any of clauses 8 through 14, wherein the first textile layer is a first material, wherein the second textile layer is a second material, and wherein the first material is different than the second material.

Clause 16. The protective garment system according to any of clauses 8 through 15, wherein the garment is pants.

Clause 17. A method for manufacturing a fluid-filled pad for a protective garment, the method comprising: positioning a first film layer overtop a second film layer such that a first exterior edge of the first film layer is aligned with a second exterior edge of the second film layer; forming a first incision through the first film layer and the second film layer, wherein the first incision is spaced inwardly from the first exterior edge and the second exterior edge; forming a second incision through the first film layer and the second film layer, the second incision extending from the first incision at an angle that is less than 180 degrees, wherein the second incision is spaced inwardly from the first exterior edge and the second exterior edge; and affixing the first film layer to the second film layer along the first exterior edge and the second exterior edge, and a periphery of the first incision and the second incision such that a fluid-filled portion is formed between the first film layer and the second film layer, the fluid-filled portion positioned inwardly from the first exterior edge and the second exterior edge and around the first incision and the second incision.

Clause 18. The method of manufacturing a fluid-filled pad for a protective system according to clause 17 further comprising: forming a third incision through the first film layer and the second film layer, wherein the third incision is spaced inwardly from the first exterior edge and the second exterior edge, and forming a fourth incision through the first film layer and the second film layer, the fourth incision extending from the third incision at an angle that is less than 180 degrees, wherein the fourth incision is spaced inwardly from the first exterior edge and the second exterior edge.

Clause 19. The method of manufacturing a fluid-filled pad for a protective system according to any of clauses 17 through 18 further comprising: positioning a first textile layer adjacent to the first film layer; positioning a second textile layer adjacent to the second film layer; and affixing the first textile layer to the second textile layer at one or more of the first incision and the second incision.

Clause 20. The method of manufacturing a fluid-filled pad for a protective system according to any of clauses 17 through 19, wherein the first incision and the second incision are linear.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples of aspects herein are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1A illustrates a perspective view of a first surface of an example fluid-filled pad in accordance with aspects herein;

FIG. 1B illustrates a perspective view of a second surface of the fluid-filled pad of FIG. 1A in accordance with aspects herein;

FIG. 2A illustrates a top plan view of the fluid-filled pad of FIG. 1A in accordance with aspects herein;

FIG. 2B illustrates a bottom plan view of the fluid-filled pad of FIG. 1A in accordance with aspects herein;

FIG. 2C illustrates a cross-section taken along cut line 2C-2C of FIG. 2A in accordance with aspects herein;

FIG. 3A illustrates a perspective view of the fluid-filled pad of FIG. 1A with textile layers and shows an example first textile layer overtop the first surface in accordance with aspects herein;

FIG. 3B illustrates a perspective view of the fluid-filled pad of FIG. 3A and shows an example second textile layer overtop the second surface in accordance with aspects herein;

FIG. 3C illustrates a cross-section taken along cut line 3C-3C of FIG. 3A in accordance with aspects herein

FIG. 4A illustrates a front view of an example protective garment system having a garment with the first and second textile layers of FIGS. 3A and 3B and the fluid-filled pad of FIG. 1A and shows an outermost-facing surface of the garment in accordance with aspects herein;

FIG. 4B illustrates a front view of the protective garment system of FIG. 4A and shows an innermost-facing surface of the garment in accordance with aspects herein;

FIG. 4C illustrates a cross-section taken at cut line 4C-4C of FIG. 4A in accordance with aspects herein;

FIG. 5A illustrates a top plan view of an example fluid-filled pad with a first alternative void configuration in accordance with aspects herein;

FIG. 5B illustrates a top plan view of an example fluid-filled pad with a second alternative void configuration in accordance with aspects herein;

FIG. 5C illustrates a top plan view of an example fluid-filled pad with a third alternative void configuration in accordance with aspects herein;

FIG. 5D illustrates a top plan view of an example fluid-filled pad with a fourth alternative void configuration in accordance with aspects herein;

FIG. 6A illustrates a front view of an example protective garment system having the fluid-filled pad of FIG. 5A in accordance with aspects herein;

FIG. 6B illustrates a front view of an example protective garment system having the fluid-filled pad of FIG. 5B in accordance with aspects herein;

FIG. 6C illustrates a front view of an example protective garment system having the fluid-filled pad of FIG. 5C in accordance with aspects herein;

FIG. 6D illustrates a front view of an example protective garment system having the fluid-filled pad of FIG. 5D in accordance with aspects herein;

FIG. 7 illustrates an example method of manufacturing a fluid-filled pad for a protective garment in accordance with aspects herein; and

FIG. 8 illustrates a flow diagram of an example method of manufacturing a fluid-filled pad for a protective garment in accordance with aspects herein.

DETAILED DESCRIPTION OF THE DRAWINGS

The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

Traditional fluid-filled pads fail to provide articulation, while maintaining suitable ventilation and protective features. Aspects herein are directed to a fluid-filled pad for a protective garment that is configured to articulate to a user's underlying body part (e.g., a thigh, hip, knee, shin, back, shoulder, chest, arm, and the like) and is also configured to provide ventilation and protection. At a high level, the fluid-filled pad includes a first surface, a second surface, a fluid-filled portion positioned between the first and second surfaces, and two or more elongate voids that extend through an entirety of the fluid-filled pad (i.e., from the first surface, through the fluid-filled portion, and to the second surface). In example aspects, the fluid-filled pad includes a first elongate void and a second elongate void extending from the first elongate void at an angle that is less than 180 degrees.

Additional aspects herein are directed to a protective garment system that includes a garment having a first and second textile layer and also includes a fluid-filled pad positioned between the first textile layer and the second textile layer. The fluid-filled pad includes a first surface, a second surface, a fluid-filled portion positioned between the first and second surfaces, a first elongate void, and a second elongate void, both of which extend through an entirety of the fluid-filled pad (i.e., from the first surface, through the fluid-filled portion, and to the second surface). Moreover, the second elongate void may extend from the first elongate void at an angle that is less than 180 degrees.

Further aspects are directed to method of manufacturing a fluid-filled pad for a protective garment that includes a first step of positioning a first film layer overtop a second film layer such that a first exterior edge of the first film layer is aligned with a second exterior edge of the second film layer. The method may further include steps of forming a first incision through the first film layer and the second film layer, forming a second incision through the first film layer and the second film layer, and affixing the first film layer to the second film layer along the first exterior edge and the second exterior edge, and a periphery of the first incision and the second incision such that a fluid-filled portion is formed between the first film layer and the second film layer, the fluid-filled portion positioned inwardly from the first exterior edge and the second exterior edge and around the first incision and the second incision.

As used herein, the term “garment” or “article of apparel” encompasses any number of products meant to be worn by a wearer including upper-body garments (e.g., shirts, vests, jackets, hoodies, tank tops, pullovers, and the like), lower-body garments (e.g., pants, shorts, leggings, and the like), articles of footwear such as shoes or socks, articles of headwear (e.g., hats, helmets, ear guards, and the like), gloves, sleeves (e.g., arm sleeves, calf sleeves, and the like), and the like. The term “protective garment” as used herein encompasses any garment or article of apparel that incorporates one or more components that cushion or protect a wearer from contact and/or impact during athletic activities. In example aspects, the protective garment is a garment that includes one or more fluid-filled pads.

Positional terms used when describing the garment, article of apparel, or protective garment such as front, back, inner-facing surface, outer-facing surface, and the like are with respect to the garment, article of apparel, or protective garment being worn as intended with the wearer standing upright. As such, when the garment, article of apparel, or protective garment is in the form of an upper-body garment, the front of the upper-body garment is configured to cover, for instance, a front upper torso area and a front arm area (when the upper-body garment has sleeves), and the back of the upper-body garment is configured to cover a back upper torso area and a back arm area (when the upper-body garment has sleeves). When the garment, article of apparel, or protective garment is in the form of a lower-body garment, the front of the lower-body garment is configured to cover, for instance, a front lower torso area and a front leg area of the wearer, and the back of the lower-body garment is configured to cover a back lower torso area and a back leg area. Similarly, the inner-facing surface of the garment, article of apparel, or protective garment is configured to be positioned to face toward a body surface of a wearer. The term “innermost-facing surface” means the surface that is positioned closest to a wearer's body surface in relation to the other surfaces and/or layers of the garment, article of apparel, or protective garment. The term “outer-facing surface” of the garment, article of apparel, or protective garment is configured to face toward the external environment or away from the inner-facing surface of the garment, article of apparel, or protective garment. The term “outermost-facing surface” means the surface that is positioned furthest away from a wearer's body surface in relation to the other surfaces and/or layers of the garment, article of apparel, or protective garment.

The term “surface plane” when used in relation to, for example, a surface of a fluid-filled pad or textile layer means a plane extending in an x-direction and a y-direction. The term “z-direction” means a direction that extends away from the respective surface plane in a positive or negative direction. Stated differently, the z-direction means a direction that is generally orthogonal to the respective surface plane. The term “edge” when used to describe the fluid-filled pad means a free or terminal edge where two or more film layers (e.g., the first and second surface) are joined together or overlap. The term “edge” when used to describe the first textile layer and/or the second textile layer means a free or terminal edge where the second textile layer is joined together with the first textile layer. The term “elongate” when used to describe a void of the fluid-filled pad means a void that has a length as measured along a surface plane of the first or second surface of the fluid-filled pad that is at least triple a width of the void as also measured along the surface plane of the first or second surface of the fluid-filled pad. The term “fluid” when describing the fluid-filled pad means a gas, including air, or a liquid including water and other liquid substances.

In example aspects, a fluid may be a pressurized gas, such as pressurized air, pressurized nitrogen, or any other pressurized gaseous compound suitable for use as a fluid in the fluid-filled pad, or a mixture of two or more pressurized gases. Such aspects contemplate that a gas may be pressurized during a manufacture of the fluid-filled pad by utilizing, for example, a device configured to produce an amount of vacuum that pressurizes the fluid-filled pad and/or a fluid-filled portion thereof to a selected degree. Aspects herein contemplate that a pressure of the fluid-filled pad, a fluid-filled portion thereof, and/or a pressurized gas contained in the fluid-filled portion may be measured using instruments and methods known by those having ordinary skill in the art. For instance, a pressure gauge may be utilized to measure and/or determine a pressure in units of pound-force per square inch (psi).

Aspects herein contemplate that at least one of a film material forming the fluid-filled pad may comprise a polyurethane film material, a thermoplastic polyurethane (TPU) film material or variants thereof (e.g., a TPU film material comprising one or more monomer portions), a thermoplastic poly(ether-amide) elastomer (TPAE) film material, and/or any film material capable of retaining a fluid within the fluid-filled pad and/or maintaining a structural integrity of the fluid-filled pad, as well as the articulation, ventilation, protection, and/or cushioning properties thereof. Further aspects herein contemplate that a film material may comprise one or more barriers and/or one or more sheets, each of which may be configured to maintain a percentage fill capacity and/or a pressure of the fluid-filled pad over time. For instance, a barrier and/or a sheet of the film material may be configured such that the fluid-filled pad maintains a generally same percentage fill capacity and/or a generally same pressure throughout a standard period of use in which the fluid-filled pad is subjected to normal wear and tear for at least three months, at least six months, at least nine months, at least one year, at least two years, or at least three years. Additional aspects herein contemplate that a film material may comprise a thickness that may be afforded to a portion of the fluid-filled pad that is formed by the film material.

In some aspects, a film material may be configured to form, at least in part, a layer and/or a surface of the fluid-filled pad. In other aspects, a film material may be included in multiples such that a same film material forms, at least in part, one or more layers and/or surfaces of the fluid-filled pad. For example, a film material may be included in duplicate such that the fluid-filled pad includes two layers and/or surfaces formed, at least in part, of a same film material. In one aspect, two layers, which may be formed, at least in part, of a same film material, may be arranged in the fluid-filled pad such that that the two layers are adjacent or stacked and in turn, form a side and/or a surface of the fluid-filled pad that comprises a bi-layer structure.

Unless otherwise noted, all measurements provided herein are measured when the garment and/or fluid-filled pad is at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar) and is in a resting (e.g., un-stretched), non-deformed state.

FIGS. 1A-1B depict an example fluid-filled pad 100 for a protective garment and illustrate respective perspective views of a first surface 110 and a second surface 120 of the fluid-filled pad 100. In example aspects, the fluid-filled pad 100 includes one or more characteristics such as dimensions, pad perimeter shape, void configuration, and the like that may be selectively altered, modified, and/or combined to afford a fluid-filled pad articulation, ventilation, protection, and/or cushioning properties that may be suitable for a particular body part of a wearer. As such, one or more characteristics of a fluid-filled pad may be based on a location at which a fluid-filled pad is incorporated into a garment and/or a body part of a wearer that is to be covered by the fluid-filled pad. For instance, a pad perimeter edge may be sized and/or arranged such that a fluid-filled pad has a pad perimeter shape that affords dimensions to the fluid-filled pad that correspond with and/or are suitable for covering a particular body part of a wearer. Taken further, a fluid-filled pad incorporated into a lower-body garment at a location that covers a wearer's thigh may have larger dimensions and a more rectangular-shaped pad perimeter shape than a fluid-filled pad incorporated at a location that covers the wearer's knee since these body parts differ in size and curvature.

As shown, the fluid-filled pad 100 includes a pad perimeter edge 102 and a pad perimeter shape referenced generally by the numeral 104. The pad perimeter edge 102 extends entirely around the fluid-filled pad 100 and defines the pad perimeter shape 104, which forms an outermost boundary of the fluid-filled pad 100. The pad perimeter shape 104 generally includes linear segments and rounded segments that that extend along, for example, a surface plane of the second surface 120 and are respectively defined by linear edges and curved edges of the pad perimeter edge 102. The linear segment extend linearly, and each linear segment has a length that is a distance a linear segment extends between two rounded segments. The rounded segments extend in a curvilinear manner and are configured to connect one linear segment to another, different linear segment. In the example of FIGS. 1A-1B, the fluid-filled pad 100 has dimensions that are suitable for covering a large body part of a wearer such as a thigh, chest, hip, buttocks, and the like, and thus, the pad perimeter shape 104 includes linear and rounded segments of the pad perimeter edge 102 that are sized and arranged such that the pad perimeter shape 104 is a generally rectangular shape with an angled top side.

The fluid-filled pad 100, as well as the first and second surfaces 110, 120, are depicted as being relatively flat, but it is to be understood that the fluid-filled pad 100 is configured to articulate in a manner that conforms to a curvature of an underlying body part of a wearer. The first surface 110 has a first exterior edge 112 that extends entirely around the first surface 110 in the fluid-filled pad 100, and in some aspects, the first exterior edge 112 may at least partially form and/or define the pad perimeter edge 102 and/or the pad perimeter shape 104 of the fluid-filled pad 100. In one example aspect, the first surface 110 extends throughout the fluid-filled pad 100, and at the first exterior edge 112, the first surface 110 is flat or extends in an x, y plane. Immediately inward from the first exterior edge 112, the first surface 110 angularly extends in a positive z-direction of the x, y plane such that a slope (not identified) is formed at a portion of the first surface 110 that is slightly inward from the pad perimeter edge 102. The first surface 110 flattens or extends in the x, y plane inward from the pad perimeter edge 102 and is relatively flat throughout a portion that is interior to the slope and uninterrupted by an elongate void. This configuration of the first surface 110 is only one example, and it is to be understood that other configurations of the first surface 110 are contemplated herein.

The second surface 120 has a second exterior edge 122 that extends entirely around the second surface 120 in the fluid-filled pad 100, and in aspects, the second exterior edge 122 may at least partially form and/or define the pad perimeter edge 102 and/or the pad perimeter shape 104 of the fluid-filled pad 100. The second surface 120 extends throughout the fluid-filled pad 100, and at the second exterior edge 122, the second surface 120 is relatively flat and remains flat as it extends inwardly from the pad perimeter edge 102. As such, the second surface 120 is relatively flat throughout the fluid-filled pad 100 but, as mentioned, is configured to articulate or bend in a manner that conforms to a curvature of an underlying body part of a wearer. Further, because the second surface 120 is depicted as being relatively flat, the second surface 120 has one surface plane in the fluid-filled pad 100. Thus, the second surface 120 and/or the surface plane thereof are used throughout this description as a reference surface in connection with discussions and/or explanations of various aspects of the fluid-filled pad 100. This configuration of the second surface 120 is only one example, and it is to be understood that other configurations of the second surface 120 are contemplated herein.

The fluid-filled pad 100 also includes a void configuration 160 that has a first elongate void 161 and a second elongate void 162 extending from the first elongate void 161. The first and second elongate voids 161, 162 are both positioned inwardly from the first exterior edge 112 of the first surface 110, as well as the second exterior edge 122 of the second surface 120. Additionally, the first and second elongate voids 161, 162 linearly extend along the surface plane of the second surface 120 and also extend in a z-direction of the surface plane of the second surface 120 through an entirety of the fluid-filled pad 100. In example aspects, and as explained further with respect to FIGS. 2A-2C, as the first and second elongate voids 161, 162 extend through the fluid-filled pad 100 from the first surface 110 toward the second surface 120, a slope (not identified) is formed on the first surface 110 that partially defines edges of the first and second elongate voids 161, 162. Continuing with these aspects, the first and second elongate voids 161, 162 then further extend entirely through the first and second surfaces 110, 120 in a direction that is substantially perpendicular (e.g., within about ±20 degrees of perpendicular) to the surface plane of the second surface 120. As such, on the first surface 110, the first and second elongate voids 161, 162 have sloped edges that collectively form a “V” shape, and at the second surface 120, the first and second elongate voids 161, 162 have vertical edges that form a narrow, linear shape. In one aspect, the “V” shape of the first and second elongate voids 161, 162 results in a gradual increase of a thickness of the fluid-filled pad 100, which reduces tearing and/or puncturing vulnerabilities of the fluid-filled pad 100 at the first and second elongate voids 161, 162. This configuration of the first and second elongate voids 161, 162 is only one example, and it is to be understood that other configurations of the first and second elongate voids 161, 162 are contemplated herein

FIGS. 2A-2C respectively depict a top plan view, a bottom plan view, and a cross-section of the fluid-filled pad 100. In FIG. 2A, the first surface 110 is shown, the second surface 120 is hidden from view, and additional aspects of the fluid-filled pad 100 are illustrated. As can be seen, the first exterior edge 112 both forms the pad perimeter edge 102 and defines the pad perimeter shape 104 on the first surface 110 of the fluid-filled pad 100. In addition, the first elongate void 161 includes a first end 163, and likewise, the second elongate void 162 includes a second end 164. The first and second elongate voids 161, 162 linearly extend from the first and second ends 163, 164, respectively and converge at a first junction 181, and in this sense, the first junction 181 is a shared end of the first and second elongate voids 161, 162 that is positioned opposite the first and second ends 163, 164. As such, the first and second elongate voids 161, 162 are joined with one another at the first junction 181. The first elongate void 161 also includes a first periphery 171 that is an edge formed by the first and second surfaces 110, 120 where the first elongate void 161 extends entirely through the fluid-filled pad 100. Similarly, the second elongate void 162 includes a second periphery 172 that is an edge formed by the first and second surfaces 110, 120 where the second elongate void 162 extends entirely through the fluid-filled pad 100.

In example aspects, at the first junction 181, the second elongate void 162 extends from the first elongate void 161 at a first angle 182 that is less than 180 degrees. In such aspects, the first angle 182 is an angle formed by an intersection of lines (not shown) superimposing a center of the first and second elongate voids 161, 162. More specifically, a first line (not shown) extends along the surface plane of the second surface 120, superposes a center of the first elongate void 161, and extends through the first end 163 and the first junction 181. A second line (not shown) extends along the surface plane of the second surface 120, superposes a center of the second elongate void 162, and extends through the second end 164 and the first junction 181. At the first junction 181, the first and second lines intersect and form an angle that is the first angle 182. Further, a degree of the first angle 182 can be determined and/or measured using methods and techniques known by those have ordinary skill in the art.

In other example aspects, the first and second lines, the intersection thereof, the first angle 182 and/or the degree of the first angle 182 may be determined and/or measured regardless of an orientation of the fluid-filled pad 100 as long as a position of the surface plane of the second surface 120 relative to the fluid-filled pad 100 is unaffected. In one aspect, the first angle 182 may be greater than 90 degrees, and in other aspects, an angle at which an elongate void extends from another elongate void may be from about 175 degrees to about 5 degrees, from about 165 degrees to about 15 degrees, from about 155 degrees to about 25 degrees, from about 145 degrees to about 35 degrees, from about 135 degrees to about 45 degrees, from about 125 degrees to about 55 degrees, from about 115 degrees to about 65 degrees, from about 105 degrees to about 75 degrees, from about 95 degrees to about 85 degrees, or may be about 90 degrees. In one example aspect, an angle at which an elongate void extends from another elongate void is less than 180 degrees. The term “about” as used herein to describe degrees of an angle means within ±4 degrees.

In FIG. 2B, the second surface 120 is shown, and the first surface 110 is hidden from view. The second exterior edge 122 both forms the pad perimeter edge 102 and defines the pad perimeter shape 104 on the second surface 120 of the fluid-filled pad 100. Additionally, the first and second surfaces 110, 120 are positioned such the first and second exterior edges 112, 122 are aligned. Moreover, on the second surface 120, the first and second elongate voids 161, 162 form narrow, linear shapes, and the first and second ends 163, 164 and the first junction 181 of the first and second elongate voids 161, 162 are observable at the second surface 120. Therefore, the degree of the first angle 182 may be determined and/or measured when only the second surface 120 of the fluid-filled pad 100 is visible in a same manner as described above.

FIG. 2C illustrates a cross-section taken at cut line 2C-C of FIG. 2A. As can be seen from this view, the first and second surfaces 110, 120 are affixed together at the first and second exterior edges 112, 122, and thus, the first and second exterior edges 112, 122 collectively form the pad perimeter edge 102 of the fluid-filled pad 100. Additionally, the first and second surfaces 110, 120 are also affixed together at the second periphery 172 of the second elongate void 162, and although not shown in FIG. 2C, the first and second surfaces 110, 120 are affixed together at the first periphery 171 of the first elongate void 161 in a same manner as the second periphery 172 of the second elongate void 162. As such, the first and second peripheries 171, 172 collectively form an edge of the fluid-filled pad 100 in the first and second elongate voids 161, 162 where the first and second surfaces 110, 120 are affixed together.

In example aspects, the first and second surfaces 110, 120 are affixed using adhesives that are melted therebetween and/or may be bonded together using heat and/or pressure. In some aspects, the first and second surfaces 110, 120 are melted together at the first and second exterior edges 112, 122 and the first and second peripheries 171, 172, and in such aspects, the first and second surfaces 110, 120 may appear as one layer at these areas. Nonetheless, a clear demarcation is shown between the first and second surfaces 110, 120 in FIGS. 2C, 3C, and 4C for illustrative purposes, and it is to be understood that such a depiction of the first and second surfaces 110, 120 at the first and second exterior edges 112, 122 and the first and second peripheries 171, 172 is not limiting.

The fluid-filled pad 100 also includes a fluid-filled portion 130 positioned between the first surface 110 and the second surface 120. In general, the fluid-filled portion 130 is located in the fluid-filled pad 100 where the first and second surfaces 110, 120 are both spaced apart (e.g., unaffixed, unattached) and uninterrupted by the first and second elongate voids 161, 162. With more detail, the fluid-filled portion 130 has an outer perimeter that extends entirely around the fluid-filled portion 130 that is defined by the first and second exterior edges 112, 122. Moreover, the fluid-filled portion 130 also has an inner perimeter extending entirely around the first and second elongate voids 161, 162 that is defined by the first and second peripheries 171, 172. Further, the fluid-filled portion 130 has a relatively planar shape, which is maintained throughout the fluid-filled pad 100.

The fluid-filled portion 130 contains a fluid 132 such as a gas, including air and/or nitrogen, and is configured to retain the fluid 132. In some aspects, the fluid-filled portion 130 may be filled to a selected percentage of its maximum fill capacity, which is the volume of the fluid 132 contained within the fluid-filled portion 130 at the point of rupture. In example aspects, the percentage fill capacity of the fluid-filled portion 130 may be from about 95% to about 5% from about 85% to about 15%, from about 75% to about 25%, from about 65% to about 35%, from about 55% to about 45%, or about 50%. The term “about” as used herein to describe a percentage fill capacity of the fluid-filled portion 130 means within ±10%. Other aspects contemplate that the fluid-filled portion 130 is configured such that a volume of the fluid 132 contained within the fluid-filled portion 130 may be selectively increased or decreased. Further aspects contemplate that the fluid 132 may be a pressurized gas, such as pressurized air, pressurized nitrogen, or any pressurized gaseous compound suitable for use as a fluid in the fluid-filled pad 100, or a mixture of two or more pressurized gases. In such aspects, the fluid 132 may be a gas that is pressurized from about 35 pound-force per square inch (psi) to about 5 psi, from about 30 psi to about 10 psi, from about 25 psi to about 15 psi, or about 20 psi. Other aspects contemplate that, when the fluid 132 is a pressurized gas, the fluid 132 may afford a pressure to the fluid-filled portion 130. As such, the fluid-filled portion 130 may include a pressure from about 35 psi to about 5 psi, from about 30 psi to about 10 psi, from about 25 psi to about 15 psi, or about 20 psi. The term “about” as used herein to describe a pressure of the fluid-filled pad 100, the fluid-filled portion 130, and/or the fluid 132 means within ±5 psi.

In aspects, the fluid-filled pad 100 may include one or more film layers formed that form at least a portion of the first surface 110, the second surface 120, or both. In such aspects, one or more film materials may be included in each of the one or more film layers and in turn, the one or more film materials may also be included in at least a portion of the first surface 110, the second surface 120, or both. As shown in FIG. 2C, the fluid-filled pad 100 includes a first film layer 140 that has a first exterior side 142 and a first interior side 144. Additionally the fluid-filled pad 100 also includes a second film layer 150 that has a second exterior side 152 and a second interior side 154. The first and second interior sides 144, 154 face an interior of the fluid-filled portion 130, and the first and second exterior sides 142, 152 face externally. In aspects, the first film layer 140, the second film layer 150, or both may be formed of a polyurethane film material, a thermoplastic polyurethane (TPU) film material or variants thereof (e.g., a TPU film material comprising one or more monomer portions), a thermoplastic poly(ether-amide) elastomer (TPAE) film material, and/or any film material capable of retaining the fluid 132 within the fluid-filled pad 100 and/or maintaining a structural integrity of the fluid-filled pad 100, as well as the articulation, ventilation, protection, and/or cushioning properties thereof. Although not depicted, aspects herein contemplate that the first surface 110, the second surface 120, the first film layer 140, the second film layer 150, or any combination thereof may include one or more additional film layers formed of an adhesive, a mesh material, one or more of the aforementioned film materials, or any combination thereof.

Although not explicitly identified, aspects herein contemplate that the fluid-filled pad 100 may include a thickness that is measureable from the first surface 110 through the fluid-filled portion 130 to the second surface 120 at a location of the fluid-filled pad 100 where the first surface 110 is flat or extends in the x, y plane and is also spaced apart from the second surface 120. In one example aspect, the fluid-filled pad 100 may have a thickness from about 10 mm to about 12 mm. Other aspects contemplate that a thickness of the fluid-filled pad 100 may be from about 2 mm to about 20 mm, from about 4 mm to about 18 mm from about 6 mm to about 16 mm, from about 8 mm to about 14 mm, or may be about 10 mm. The term “about” as used herein to describe a thickness of the fluid-filled pad 100 means within ±2 mm. Similarly, aspects herein contemplate that each of the first and second film layers 140, 150 may also include a thickness. In such aspects, a thickness of the first film layer 140 is measurable from the first exterior side 142 to the first interior side 144, and likewise, a thickness of the second film layer 150 is measurable from the second exterior side 152 to the second interior side 154. Example aspects herein contemplate that a thickness of the first film layer 140, the second film layer 150, or both may be from about 0.25 mm to about 2.25 mm, from about 0.5 mm to about 2.0 mm, from about 0.75 mm to about 1.75 mm, from about 1.0 mm to about 1.5 mm, or about 1.25 mm. In one example aspect, a thickness of the first film layer 140, the second film layer 150, or both is about 0.55 mm, about 1.14 mm, about 1.4 mm, about 1.65 mm, or about 1.9 mm. The term “about” as used herein to describe a thickness of the first film layer 140, the second film layer 150, or both means within ±0.25 mm.

In additional aspects, the fluid-filled pad 100 may have an overall shape extending in the z-direction of a surface plane of the second surface 120 that differs from what is depicted in FIG. 2C. For instance, in one aspect, the second surface 120 may extend in the fluid-filled pad 100 in a manner that is similar to the first surface 110 such that near the second exterior edge 122 and the first and second elongate voids 161, 162, slopes are formed on the second surface 120. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

FIGS. 3A-3C depict the fluid-filled pad 100 with an example first textile layer 310 and an example second textile layer 320. In aspects, the first and second textile layers 310, 320 are configured to be used to construct a garment and have one or more characteristics (e.g., material composition, moisture-wicking ability, weight, breathability, elasticity or stretch and recovery, shape, and the like) that can be selectively included in the first and second textile layers 310, 320 to impart features and/or properties to the garment. For instance, the first textile layer 310 may be formed of a lightweight material and may have a shape that is suitable for a panel of a lower-body garment, and the second textile layer 320 may be formed of a thin material composition and may have a shape that is suitable for an interior panel of the lower-body garment. In FIGS. 3A-3C, at least some of the characteristics of the first and second textile layers 310, 320 are shown in a simplified fashion or are not depicted, but it is to be understood that each of the first and second textile layers 310, 320 may include any combination of characteristics discussed herein.

In example aspects the first textile layer 310 has a first material composition and the second textile layer 320 has a second material composition. In one such aspect, the first material composition of the first textile layer 310 is different than the second material composition of the second textile layer 320. Further aspects contemplate that the first material composition includes a woven textile, a knit textile, a non-woven textile, and the like. Even further aspects contemplate that the second material composition includes a woven textile, a knit textile, a non-woven textile, and the like. In one example aspect, the first material composition of the first textile layer 310 is a nylon fabric that is a recycled nylon woven fabric.

FIG. 3A is a perspective view illustrating the first textile layer 310 on the first surface 110 of the fluid-filled pad 100, and FIG. 3B is a perspective view illustrating the second textile layer 320 on the second surface 120 of the fluid-filled pad 100. As shown, the first and second textile layers 310, 320 entirely cover the fluid-filled pad 100 and are arranged such that the first textile layer 310 is positioned adjacent to the first surface 110 of the fluid-filled pad 100, and the second textile layer 320 is positioned adjacent to the second surface 120. Thus, the fluid-filled pad 100 and in turn, the first and second surfaces 110, 120 are hidden from view by the first and second textile layers 310, 320, but because of a manner in which the first and second textile layers 310, 320 are configured and/or combined with the fluid-filled pad 100, structural changes in a z-direction on the first and second surfaces 110, 120 are visually observable through the first and second textile layers 310, 320. Specifically, in FIG. 3A, slope portions of the first surface 110, the void configuration 160, and the first and second elongate voids 161, 162 of the fluid-filled pad 100 are at least partially visible though the first textile layer 310, and similarly, the pad perimeter edge 102, the pad perimeter shape 104, the void configuration 160, and the first and second elongate voids 161, 162 are at least partially visible though the second textile layer 320 in FIG. 3B.

The first textile layer 310 includes a first externally facing surface 312, a first internally facing surface 314 positioned opposite the first externally facing surface 312, and a first external edge 316. When the first textile layer 310 is incorporated into a garment, the first externally facing surface 312 would face toward an external environment of the garment, and the first internally facing surface 314 would face towards a body surface of a wearer. The first external edge 316 extends entirely around the first textile layer 310 and defines a textile perimeter shape of the first textile layer 310, which is generically depicted as a rectangle. In other aspects, the first textile layer 310 may be configured to have a textile perimeter shape (e.g., a pattern shape) that is commonly used for construction of a garment and/or may form a textile perimeter shape that is specific and/or suitable for an end use of the garment.

The second textile layer 320 includes a second externally facing surface 322 (identified in FIG. 3C), a second internally facing surface 324 positioned opposite the second externally facing surface 322, a second external edge 326, and a textile perimeter shape that is referenced generally by the numeral 328. When the second textile layer 320 is included in a garment, the second externally facing surface 322 faces toward an external environment, and the second internally facing surface 324 faces towards a body surface of a wearer. The second external edge 326 extends entirely around the second textile layer 320 and defines the textile perimeter shape 328. In example aspects, and as further discussed with respect to FIG. 3C, the first and second textile layers 310, 320 are affixed to one another along the second external edge 326 and at the first and second elongate voids 161, 162.

In example aspects, and as shown in FIG. 3B, the textile perimeter shape 328 of the second textile layer 320 is substantially the same as the pad perimeter shape 104 of the fluid-filled pad 100. As used herein, the term “substantially the same” means the perimeter shapes share the same geometric configuration but may differ slightly in dimensions. For example, edges forming the textile perimeter shape 328 of the second textile layer 320 may be slighter longer than the edges that form the pad perimeter shape 104 of the fluid-filled pad 100. Having the pad and textile perimeter shapes 104, 328 be substantially the same helps secure a position of the fluid-filled pad 100, while minimizing a surface area of the second textile layer 320.

FIG. 3C illustrates a cross-section of the fluid-filled pad 100 with the first and second textile layers 310, 320 taken at cut line 3C-C of FIG. 3A. In FIG. 3C, the fluid-filled pad 100 includes the same features and/or aspects as those that are identified and discussed in connection with FIGS. 2A-2C, and thus, for purposes of brevity, many aspects of the fluid-filled pad 100 are not repeated. Notwithstanding, as can be seen in FIG. 3C, the first textile layer 310 is positioned on the first surface 110 of the fluid-filled pad 100 such that the first internally facing surface 314 is contiguous with the first surface 110 and the first externally facing surface 312 faces away from the fluid-filled pad 100. The second textile layer 320 is positioned on the second surface 120 of the fluid-filled pad 100 such that the second externally facing surface 322 is contiguous with the second surface 120 of the fluid-filled pad 100 and the second internally facing surface 324 faces away from the fluid-filled pad 100. In example aspects, the first textile layer 310 is secured to the first surface 110 of the fluid-filled pad 100 at the first internally facing surface 314 via an adhesive and/or bonding. Likewise, the second textile layer 320 is secured to the second surface 120 of the fluid-filled pad 100 at the second externally facing surface 322 via an adhesive and/or bonding.

The first and second textile layers 310, 320 are further positioned such that the first internally facing surface 314 is contiguous with the second externally facing surface 322 around the pad perimeter edge 102, at the first elongate void 161 (not shown), and at the second elongate void 162. In example aspects, the second textile layer 320 is affixed to the first textile layer 310 at the second external edge 326 and at the first and second elongate voids 161, 162 via an adhesive, bonding, stitching, and the like.

FIGS. 4A-4C depict an example protective garment system 400 that includes an example lower-body garment 402 with the first and second textile layers 310, 320 and the fluid-filled pad 100. FIG. 4A illustrates a front view of the protective garment system 400 and shows an outermost-facing surface 404 of the lower-body garment 402. In this example, the lower-body garment 402 is depicted as a pant, and specifically an American football pant, and as being formed of the first textile layer 310. As such, the first externally facing surface 312 of the first textile layer 310 is the outermost-facing surface 404 of the lower-body garment 402. The first textile layer 310 is positioned on the fluid-filled pad 100 such that the pad perimeter edge 102, the void configuration 160, and the first and second elongate voids 161, 162 are visually observable when viewed from the outermost-facing surface 404. Furthermore, the first angle 182 at which the second elongate void 162 extends from the first elongate void 161 is also visually observable when viewed from the outermost-facing surface 404. As such, the degree of the first angle 182 may be determined and/or measured when the fluid-filled pad 100 is included in a garment in a same manner as discussed above in connection with FIGS. 2A-2C, and in this example, the first angle 182 is less than 180 degrees.

The fluid-filled pad 100 is located in the lower-body garment 402 at an anterior thigh area of a left leg portion. Although not identified, three additional fluid-filled pads having alternative pad perimeter edges and void configurations may be located in the lower-body garment 402 at other areas. As such, a first alternative fluid-filled pad that is a mirror image of the fluid-filled pad 100 is located in the lower-body garment 402 at an anterior thigh area of a right leg portion. Moreover, a second alternative fluid-filled pad and a third alternative fluid-filled pad that is mirror image of the second alternative fluid-filled pad are respectively located in the lower-body garment 402 at anterior knee areas of the left and right leg portions. The location and placement of the fluid-filled pads is illustrative only, and it is contemplated herein that the lower-body garment 402 may include additional fluid-filled pads or fewer fluid-filled pads positioned at different locations than that shown.

FIG. 4B illustrates a front view of the protective garment system 400 and shows an innermost-facing surface 406 of the lower-body garment 402. In this example, the lower-body garment 402 is depicted as including a “patch” on an interior of the lower-body garment 402 that extends overtop the fluid-filled pad 100 and that is formed from the second textile layer 320. As used herein, the term “patch” is used to indicate that the textile forming the second textile layer 320 has a smaller surface area than the first textile layer 310. In one aspect, the surface area of the second textile layer 320 may be from about 10% to about 20% larger than the surface area of the fluid-filled pad 100. In addition, the lower-body garment 402 is depicted as including three additional patches on the interior that extend overtop the three additional fluid-filled pads and that are formed of the second textile layer 320. As such, at areas of the interior that include a patch, the second internally facing surface 324 of the second textile layer 320 is the innermost-facing surface 406 of the lower-body garment 402, and at areas of the interior where a patch is absent, the first internally facing surface 314 of the first textile layer 310 is the innermost-facing surface 406 of the lower-body garment 402. Moreover, the second external edge 326 of the second textile layer 320 that forms the patch extending overtop the fluid-filled pad 100 is substantially the same shape as the pad perimeter edge 102. Further, the second textile layer 320 that forms the patch extending overtop the fluid-filled pad 100 is positioned such that the pad perimeter edge 102, the void configuration 160, and the first and second elongate voids 161, 162 are visible at the innermost-facing surface 406. In addition, the aforementioned features and/or aspects of the second textile layer 320 are also included at the three additional patches that extend overtop the three additional fluid-filled pads.

FIG. 4C illustrates a cross-section of the protective garment system 400 taken at cut line 4C-4C of FIG. 4A. As shown, in the lower-body garment 402, the fluid-filled pad 100 and the first and second textile layers 310, 320 have the same features, aspects, configurations and/or arrangement as those that are discussed and described above in connection with FIG. 3C. Accordingly, the first textile layer 310 and the second textile layer 320 are positioned such that the first internally facing surface 314 of the first textile layer 310 is contiguous with the second externally facing surface 322 of the second textile layer 320 around the pad perimeter edge 102, at the first elongate void 161 (not shown), and at the second elongate void 162. In example aspects, the second textile layer 320 is affixed to the first textile layer 310 at the second external edge 326 and at the first and second elongate voids 161, 162 via an adhesive, bonding, stitching, and the like.

As mentioned, the fluid-filled pad described herein may include a pad perimeter shape and/or void configurations based on, for example, a curvature, size, and/or heat generation map of an underlying body part of a wearer. FIG. 5A-5D illustrate some example pad perimeter shapes and/or void configurations for the fluid-filled pad described herein. FIG. 5A illustrates a top plan view of an example first fluid-filled pad 510 that has an example first pad perimeter shape 514 and includes an example first void configuration 190. As shown the first pad perimeter shape 514 is generally elliptical with a projection emerging from one of the corners, and in aspects, the first pad perimeter shape 514 is configured to cover a knee or small body part of a wearer (e.g., forearm, elbow, upper arm, ankle, calf, and the like). The first void configuration 190 includes a first elongate void 191, a second elongate void 192, a third elongate void 193, and a fourth elongate void 194, all of which are positioned inward from an exterior edge of a first surface of the pad (not identified). Additionally, the second elongate void 192 extends from the first elongate void 191 at a first angle 202 that is less than 180 degrees, and similarly, the fourth elongate void 194 extends from the third elongate void 193 at a second angle 204 that is less than 180 degrees. Both the first and second angles 202, 204 may be determined and/or measured in a same manner as discussed above in connection with FIGS. 2A-2C. Further, in the first fluid-filled pad 510, the first and second elongate voids 191, 192 are spaced apart from the third and fourth elongate voids 193, 194.

FIG. 5B illustrates a top plan view of an example second fluid-filled pad 520 that has an example second pad perimeter shape 524 and includes an example second void configuration 220. The second pad perimeter shape 524 is similar to the pad perimeter shape 104 of the fluid-filled pad 100 and thus, is also configured to cover a thigh or large body part of a wearer (e.g., hamstring, buttocks, chest, and the like). The second void configuration 220 includes a first elongate void 221, a second elongate void 222, a third elongate void 223, a fourth elongate void 224, a fifth elongate void 225, and a sixth elongate void 226 that are all positioned inward from an exterior edge of a first surface of the second fluid-filled pad 520. Moreover, the second elongate void 222 extends from the first elongate void 221 at a first angle 232 that is less than 180 degrees, the fourth elongate void 224 extends from the third elongate void 223 at a second angle 234 that is less than 90 degrees, and the sixth elongate void 226 extends from the fifth elongate void 225 at a third angle 236 that is less than 180 degrees. Like the other angles discussed herein, the first, second, and third angles 232, 234, 236 may be determined and/or measured in a same manner as discussed above in connection with FIGS. 2A-2C. Furthermore, each pair of elongate voids (i.e., the first and second elongate voids 221, 222, the third and fourth elongate voids 223, 224, and the fifth and sixth elongate voids 225, 226) are each spaced apart from one another in the second fluid-filled pad 520.

FIG. 5C illustrates a top plan view of an example third fluid-filled pad 530 that has an example third pad perimeter shape 534 and includes an example third void configuration 250. The third pad perimeter shape 534 is similar to and different than the second pad perimeter shape 524 of the second fluid-filled pad 520 and the pad perimeter shape 104 of the fluid-filled pad 100. For example, the third pad perimeter shape 534 is also configured to cover a thigh or large body part of a wearer (e.g., hamstring, buttocks, chest, and the like), but unlike the second pad perimeter shape 524 and the pad perimeter shape 104, the third pad perimeter shape 534 has a top edge that is mostly formed of one linear segment. The third void configuration 250 includes a first elongate void 251, a second elongate void 252, a third elongate void 253, a fourth elongate void 254, a fifth elongate void 255, a sixth elongate void 256, a seventh elongate void 257, and an eighth elongate void 258, all of which are positioned inward from an exterior edge of a first surface of the third fluid-filled pad 530. Additionally, the second elongate void 252 extends from the first elongate void 251 at a first angle 262 that is less than 180 degrees, the fourth elongate void 254 extends from the third elongate void 253 at a second angle 264 that is less than 180 degrees, the sixth elongate void 256 extends from the fifth elongate void 255 at a third angle 266 that is less than 180 degrees, and the eighth elongate void 258 extends from the seventh elongate void 257 at a fourth angle 268 that is also less than 180 degrees Like the other angles discussed herein, the first, second, third, and fourth angles 262, 264, 266, 268 may be determined and/or measured in a same manner as discussed above in connection with FIGS. 2A-2C. Furthermore, each pair of elongate voids (i.e., the first and second elongate voids 251, 252, the third and fourth elongate voids 253, 254, the fifth and sixth elongate voids 255, 256, and the seventh and eighth elongate voids 257, 258) are each spaced apart from one another in the third fluid-filled pad 530.

FIG. 5D illustrates a top plan view of an example fourth fluid-filled pad 540 that has an example fourth pad perimeter shape 544 and includes an example fourth void configuration 280. The fourth pad perimeter shape 544 is generally rectangular and is configured to cover a large body part of a wearer (e.g., thigh, hamstring, buttocks, chest, and the like). The fourth void configuration 280 includes a first elongate void 281, a second elongate void 282, a third elongate void 283, a fourth elongate void 284, a fifth elongate void 285, a sixth elongate void 286, a seventh elongate void 287, an eighth elongate void 288, a ninth elongate void 289, and a tenth elongate void 290 that are all positioned inward from an exterior edge of a first surface of the fourth fluid-filled pad 540. Additionally, the second elongate void 282 extends from the first elongate void 281 at a first angle 292 that is less than 180 degrees, the fourth elongate void 284 extends from the third elongate void 283 at a second angle 294 that is less than 180 degrees, the sixth elongate void 286 extends from the fifth elongate void 285 at a third angle 296 that is less than 90 degrees, the eighth elongate void 288 extends from the seventh elongate void 287 at a fourth angle 298 that is less than 180 degrees, and the tenth elongate void 290 extends from the ninth elongate void 289 at a fifth angle 300 that is less than 180 degrees. Like the other angles discussed herein, the first, second, third, fourth, and fifth angles 292, 294, 296, 298, 300 may be determined and measured in a same manner as discussed above in connection with FIGS. 2A-2C. Furthermore, each pair of elongate voids (i.e., the first and second elongate voids 281, 282, the third and fourth elongate voids 283, 284, the fifth and sixth elongate voids 285, 286, the seventh and eighth elongate voids 287, 288, and the ninth and tenth elongate voids 289, 290) are each spaced apart from one another in the fourth fluid-filled pad 540.

In aspects, any elongate void of the void configuration 160 or the first, second, third, and fourth void configurations 190, 220, 250, 280 may be duplicated or combined with another elongate void thereof to form an angle at which an elongate void extends from another elongate void. Such an angle may be from about 175 degrees to about 5 degrees, from about 165 degrees to about 15 degrees, from about 155 degrees to about 25 degrees, from about 145 degrees to about 35 degrees, from about 135 degrees to about 45 degrees, from about 125 degrees to about 55 degrees, from about 115 degrees to about 65 degrees, from about 105 degrees to about 75 degrees, from about 95 degrees to about 85 degrees, or may be about 90 degrees. The term “about” as used herein to describe degrees of an angle means within ±4 degrees.

In further aspects, pairs of elongate voids including any elongate void of the void configuration 160 or the first, second, third, and fourth void configurations 190, 220, 250, 280 may be duplicated or combined with another elongate void thereof to form any of the aforementioned angles at which an elongate void extends from another elongate void may be duplicated and/or combined with other pairs of elongate voids in a fluid-filled pad. Additionally, such a fluid-filled pad may include any pad perimeter shape similar to or different than the pad perimeter shape 104 or the first, second, third, and fourth pad perimeter shapes 514, 524, 534, 544. Further, such a fluid-filled pad may also be included in a garment, like the lower-body garment 402, and in a same or similar manner as the fluid-filled pad 100 is included in the lower-body garment 402 to form the protective garment system 400. Some examples of protective garment systems are discussed below in connection with FIGS. 6A-6D.

In even further aspects, the elongate voids and the configurations of multiple elongate voids described herein are configured to afford functional properties to a fluid-filled pad. Such functional properties include breathability and articulation, both of which may be tailored to a particular body party of a wearer that is to be covered by the fluid-filled pad. In more detail, because the elongate voids extend entirely through the fluid-filled pad, they may function as vents or cooling areas that allow for ventilation at an underlying body of a wearer. Moreover, an extension of the elongate voids entirely through the fluid-filled pad also results in improved flexibility at locations of the fluid-filled pad that include elongate voids since these locations are uninhibited by structural connections. Furthermore, the elongate voids may have a configuration in which pairs of elongate voids are angled in a manner that allows the fluid-filled pad to be more articulable in one direction than another, different directions. As such, a configuration of elongate voids may be configured to afford articulation properties to the fluid-filled pad that are complimentary to a curvature and/or movement of an underlying body part of a wearer.

FIG. 6A illustrates a front view of an example first protective garment system 610 that includes an example first lower-body garment 612 with a first outermost-facing surface 614 and also includes the first fluid-filled pad 510. The first protective garment system 610 includes the same features as the protective garment system 400. For instance, the first protective garment system 610 includes the first outermost-facing surface 614 of the first lower-body garment 612, which may be formed of a textile layer like the first textile layer 310. Continuing, the first lower-body garment 612 is depicted as a pant and a first externally facing surface of the textile layer is the first outermost-facing surface 614 of the first lower-body garment 612, which is configured such that the first pad perimeter shape 514 (not identified) and the first void configuration 190 (not identified) are visually observable when looking at the first outermost-facing surface 614. Furthermore, the first fluid-filled pad 510 is located in the first lower-body garment 612 at an anterior knee area of a left leg portion. Although not depicted, additional fluid-filled pads with a same or alternative pad perimeter edge and void configuration may also be included in the first lower-body garment 612 at other areas.

FIG. 6B illustrates a front view of an example second protective garment system 620 that includes an example second lower-body garment 622 with a second outermost-facing surface 624 and the second fluid-filled pad 520. Like the first protective garment system 610, the second protective garment system 620 also includes the same features as the protective garment system 400. The second lower-body garment 622 is depicted as a pant and a first externally facing surface of a textile layer is the second outermost-facing surface 624 of the second lower-body garment 622, which is configured such that the second pad perimeter shape 524 (not identified) and the second void configuration 220 (not identified) are visually observable when looking at the second outermost-facing surface 624. Further, the second fluid-filled pad 520 is located in the second lower-body garment 622 at an anterior thigh area of a left leg portion. While not depicted, additional fluid-filled pads with a same or alternative pad perimeter edge and void configuration may also be included in the second lower-body garment 622 at other areas.

FIG. 6C illustrates a front view of an example third protective garment system 630 that includes an example third lower-body garment 632 with a third outermost-facing surface 634 and the third fluid-filled pad 530. Like the first and second protective garment systems 610, 620, the third protective garment system 630 also includes the same features as the protective garment system 400. As such, the third lower-body garment 632 is also depicted as a pant and a first externally facing surface of a textile layer is the third outermost-facing surface 634 of the third lower-body garment 632, which is configured such that the third pad perimeter shape 534 (not identified) and the third void configuration 250 (not identified) are visually observable when looking at the third outermost-facing surface 634. Further, the third fluid-filled pad 530 is located in the third lower-body garment 632 at an anterior thigh area of a left leg portion. Even though it is not depicted, additional fluid-filled pads with a same or alternative pad perimeter edge and void configuration may also be included in the third lower-body garment 632 at other areas.

FIG. 6D illustrates a front view of an example fourth protective garment system 640 that includes an example fourth lower-body garment 642 with a fourth outermost-facing surface 644 and the fourth fluid-filled pad 540. Like the first, second, and third protective garment systems 610, 620, 630, the fourth protective garment system 640 also includes the same features as the protective garment system 400. Therefore, the fourth lower-body garment 642 is also depicted as a pant and a first externally facing surface of a textile layer is the fourth outermost-facing surface 644 of the fourth lower-body garment 642, which is configured such that the fourth pad perimeter shape 544 (not identified) and the fourth void configuration 280 (not identified) are visually observable when viewing the fourth outermost-facing surface 644. The fourth fluid-filled pad 540 is located in the fourth lower-body garment 642 at an anterior thigh area of a left leg portion. Although not depicted, additional fluid-filled pads with a same or alternative pad perimeter edge and void configuration may also be included in the fourth lower-body garment 642 at other areas. In addition, even though only lower-body garments are depicted, it is contemplated herein that the fluid-filled pads described herein may be incorporated into an upper-body garment.

FIG. 7 illustrates an example method of manufacturing 700 the fluid-filled pad 100 for the protective garment system 400, which includes example steps of forming the fluid-filled pad 100 and incorporating the fluid-filled pad 100 into the lower-body garment 402. At a step 702, the first film layer 140 is positioned overtop the second film layer 150 such that a first exterior edge of the first film layer 140 is aligned with a second exterior edge of the second film layer 150. As such, the first and second film layers 140, 150 are positioned such that the first surface 110 of the fluid-filled pad 100 is formed by the first film layer 140 and the second surface 120 of the fluid-filled pad 100 is formed by the second film layer 150. In some aspects, an adhesive layer and/or other layers may be included between the first and second film layers 140, 150 along the first and second edges and/or interior thereto. In an alternative aspect, an adhesive layer may be included as part of the first film layer 140, the second film layer 150, or both.

At a step 704, a first incision is formed through the first and second film layers 140, 150 and inward from the first and second exterior edges that becomes the first elongate void 161. Similarly, at a step 706, a second incision is formed through the first and second film layers 140, 150 and inward from the first and second exterior edges that becomes the second elongate void 162. Accordingly, the second incision is formed in a manner such that it extends from the first incision at the first angle 182 (not identified). In aspects, the first and/or second incisions are linear and may be formed using cutting devices and/or by applying heat in a selective manner that causes the first and second film layers 140, 150 to be dissolved or melted at an applied area. In further aspects, the steps 704 and 706 may be repeated to form additional incisions (e.g., a third and fourth incision, a fifth and sixth incision, a seventh and eighth incision, and/or a ninth and tenth incision) that become additional elongate voids, such as those discussed above in connection with FIGS. 5A-5D.

At a step 708, the first film layer 140 is affixed to the second film layer 150 along the first and second exterior edges and a periphery of the first and second incisions such that a fluid-filled portion is formed between the first and second film layers 140, 150 inwardly from the first and second exterior edges and around the first and second incisions, as is shown in a step 710. In aspects, a first device 730 is used to apply heat and/or pressure to the first and/or second film layers at one or more of the first and second exterior edges and a periphery of the first and second incisions that are configured such that the first and second film layers 140, 150 affix to one another along the first and second exterior edges and the periphery of the first and second incisions. In some aspects, the first device 730 may be configured such that the first and second film layers 140, 150 are laminated and/or melted together or to melt an adhesive layer positioned between the first and second film layers and along the periphery of the first and second incisions. In aspects, the first device 730 may include a radio-frequency welder but other bonding techniques are contemplated herein. Additionally, a second device 734 that is used to apply a vacuum that ensures that a fluid, such as air, is trapped or sealed within the resulting fluid-filled portion as shown the step 710. The second device 734 may be configured to produce an amount of vacuum that may be adjusted to ensure that the fluid-filled portion is filled to a selected capacity and/or that the fluid-filled portion is pressurized to a selected degree. In example aspects, the fluid-filled portion may include a pressure from about 35 psi to about 5 psi, from about 30 psi to about 10 psi, from about 25 psi to about 15 psi, or about 20 psi.

At the step 710, the fluid-filled pad 100 has been formed that includes the fluid-filled portion 130 between the first and second film layers 140, 150 (e.g., the first and second surfaces 110, 120) and around the first and second incisions (e.g., the first and second elongate voids 161, 162) and that also includes the void configuration 160. This may be done by affixing the first and second exterior edges and the periphery of the first and second incisions while maintaining an alignment of the first and second film layers 140, 150 and simultaneously applying a vacuum that ensures that a fluid, such as air, is trapped or sealed within the resulting fluid-filled portion as shown the step 710.

Then, at a step 712, the fluid-filled pad 100 is combined with the first and second textile layers 310, 320. As shown, the first textile layer 310 is positioned adjacent to the first film layer 140 and the second textile layer 320 is positioned adjacent to the second film layer 150. In aspects, a textile perimeter edge of the second textile layer 320 and a pad perimeter edge of the fluid-filled pad 100 are substantially the same, and the second textile layer 320 is positioned such that the textile perimeter edge extends around the pad perimeter edge of the fluid-filled pad 100, like a patch.

At a step 714, the first textile layer 310 is affixed to the second textile layer 320 around the pad perimeter edge of the fluid-filled pad 100 and/or at one or more of the first incision and the second incision (e.g., the first and second elongate voids 161, 162). In aspects, a third device 732 is used to apply heat and/or pressure to the first and second textile layers 310, 320 that are configured such that the first and second textile layers 310, 320 affix and/or bond to one another. In some aspects, an adhesive layer and/or other layers may be included between the first and second textile layers 310, 320 along the textile perimeter edge of the second textile layer 320, between the first and second incisions, between the first textile layer 310 and the first film layer 140, and/or between the second textile layer 320 and the second film layer 150. Continuing with these aspects, the adhesive layer may be configured such that it is melted by the third device 732 and then bonds, affixes, and/or joins the first and second textile layers 310, 320 to one another and/or to the first and second film layers 140, 150.

At a step 716, the fluid-filled pad 100 is shown as combined with the first and second textile layers 310, 320, which, at a step 718 are then incorporated into a protective garment. In this example, the protective garment is depicted as the lower-body garment 402. Although not explicitly shown, the first textile layer 310 may be shaped such that is forms a panel of the lower-body garment 402 in which the fluid-filled pad 100 is located at an anterior thigh of a left leg portion of the lower-body garment 402. In additional aspects, any of the steps 702 through 716 may be repeated and/or duplicated to create additional combinations of the fluid-filled pad 100 and the first and second textile layers 310, 320 that may also be incorporated into a same or different protective garment. For example, an additional fluid-filled pad could be formed in accordance with the steps 702 through 710 that is a mirror image of the fluid-filled pad 100, combined with the first and second textile layers 310, 320 in accordance with the steps 712 through 716, and then incorporated into a protective garment in accordance with the step 718 such that the first textile layer 310 forms a panel of the lower-body garment 402 in which the fluid-filled pad 100 is located at an anterior thigh of a right leg portion of the lower-body garment 402.

FIG. 8 illustrates a flow diagram of an example method of manufacturing 800 a fluid-filled pad for a protective garment and incorporating the fluid-filled pad into a garment. As shown, steps of the method of manufacturing 800 are similar to those discussed immediately above in connection with the method of manufacturing 700. As such, at a block 802, a first step of the method is depicted, which includes positioning a first film layer overtop a second film layer such that an exterior edge of each film layer are aligned. A block 804 depicts a second step of forming a first incision through the first and second film layers and inward from the exterior edges, and a block 806 depicts a third step of forming a second incision through the first and second film layers and inward from the exterior edges. At a block 808, a fourth step is depicted of affixing the first film layer to the second film layer along the exterior edges and a periphery of the first and second incisions such that a fluid-filled portion between the first and second film layers is formed. Although not depicted at the block 808, aspects herein contemplate that the fourth step may also include simultaneously applying a vacuum that ensures that a fluid, such as air, is trapped or sealed within the resulting fluid-filled portion. In one aspect, an amount of vacuum may be adjusted to ensure that the fluid-filled portion is filled to a selected capacity.

A block 810 depicts a fifth step of positioning a first textile layer adjacent to the first film layer, and a block 812 depicts a sixth step of positioning a second textile layer adjacent to the second film layer. At a block 814, a seventh step is depicted of affixing the first textile layer to and the second textile layer at one or more of the first and second incisions, and at a block 816, an eighth step is depicted of constructing a protective garment with the first and second textile layers and the fluid-filled pad.

In aspects, it is contemplated that the methods of manufacturing 700, 800 may be utilized to manufacture a variety of fluid-filled pads with different pad perimeter shapes and void configurations, to combine such fluid-filled pads with textile layers, and/or to construct a protective garment using such fluid-filled pads and textile layers. As such, aspects herein contemplate that the methods of manufacturing 700, 800 may be utilized to manufacture the fluid-filled pad 100, the first, second, third, fourth fluid-filled pads 510, 520, 530, 540, and/or combinations thereof. Further aspects contemplate that that the methods of manufacturing 700, 800 may be utilized to construct the protective garment system 400, the first, second, third, fourth protective garment systems 610, 620, 630, 640, and/or combinations thereof.

Aspects of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure.

It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described. 

What is claimed is:
 1. A fluid-filled pad for a protective garment, the fluid-filled pad comprising: a first surface having an exterior edge; a second surface positioned opposite the first surface, the second surface affixed to the first surface along the exterior edge; a fluid-filled portion positioned between the first surface and the second surface; a first elongate void positioned inwardly from the exterior edge of the first surface, the first elongate void extending through the first surface, the fluid-filled portion, and the second surface; and a second elongate void positioned inwardly from the exterior edge of the first surface, the second elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the second elongate void extends from the first elongate void at an angle that is less than 180 degrees.
 2. The fluid-filled pad of claim 1, wherein each of the first elongate void and the second elongate void extend linearly.
 3. The fluid-filled pad of claim 1, wherein the first surface is affixed to the second surface along a periphery of the first elongate void and the second elongate void.
 4. The fluid-filled pad of claim 1 further comprising: a first textile layer positioned adjacent to the first surface of the fluid-filled pad; and a second textile layer positioned adjacent to the second surface of the fluid-filled pad, wherein the first textile layer is affixed to the second textile layer at one or more of the first elongate void and the second elongate void.
 5. The fluid-filled pad of claim 1 further comprising a third elongate void positioned inwardly from the exterior edge of the first surface, the third elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the third elongate void is spaced apart from the first elongate void and the second elongate void.
 6. The fluid-filled pad of claim 1 further comprising: a third elongate void positioned inwardly from the exterior edge of the first surface, the third elongate void extending through the first surface, the fluid-filled portion, and the second surface; and a fourth elongate void positioned inwardly from the exterior edge of the first surface, the fourth elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the fourth elongate void extends from the third elongate void at an angle that is less than 180 degrees.
 7. The fluid-filled pad of claim 6 further comprising a fifth elongate void positioned inwardly from the exterior edge of the first surface, the fifth elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the fifth elongate void is spaced apart from the first elongate void, the second elongate void, the third elongate void, and the fourth elongate void.
 8. A protective garment system comprising: a garment having a first textile layer and a second textile layer; and a fluid-filled pad positioned between the first textile layer and the second textile layer, the fluid-filled pad comprising: a first surface having an exterior edge, a second surface positioned opposite the first surface, the second surface affixed to the first surface along the exterior edge, a fluid-filled portion positioned between the first surface and the second surface, a first elongate void positioned inwardly from the exterior edge of the first surface, the first elongate void extending through the first surface, the second surface, and the fluid-filled portion, and a second elongate void positioned inwardly from the exterior edge of the first surface, the second elongate void extending through the first surface, the second surface, and the fluid-filled portion, wherein the second elongate void extends from the first elongate void at an angle that is less than 180 degrees.
 9. The protective garment system of claim 8, wherein the first textile layer is affixed to the second textile layer around the exterior edge.
 10. The protective garment system of claim 8, wherein the first textile layer is affixed to the second textile layer at the first elongate void and at the second elongate void.
 11. The protective garment system of claim 8 further comprising: a third elongate void positioned inwardly from the exterior edge of the first surface, the third elongate void extending through the first surface, the fluid-filled portion, and the second surface; and a fourth elongate void positioned inwardly from the exterior edge of the first surface, the fourth elongate void extending through the first surface, the fluid-filled portion, and the second surface, wherein the fourth elongate void extends from the third elongate void at an angle that is less than 180 degrees.
 12. The protective garment system of claim 11, wherein the first textile layer is affixed to the second textile layer around the exterior edge, at the first elongate void, at the second elongate void, at the third elongate void, and at the fourth elongate void.
 13. The protective garment system of claim 8, wherein the first textile layer forms the garment.
 14. The protective garment system of claim 8, wherein the second textile layer forms a patch on an interior of the garment that extends overtop the fluid-filled pad.
 15. The protective garment system of claim 8, wherein the first textile layer is a first material, wherein the second textile layer is a second material, and wherein the first material is different than the second material.
 16. The protective garment system of claim 8, wherein the garment is pants.
 17. A method for manufacturing a fluid-filled pad for a protective garment, the method comprising: positioning a first film layer overtop a second film layer such that a first exterior edge of the first film layer is aligned with a second exterior edge of the second film layer; forming a first incision through the first film layer and the second film layer, wherein the first incision is spaced inwardly from the first exterior edge and the second exterior edge; forming a second incision through the first film layer and the second film layer, the second incision extending from the first incision at an angle that is less than 180 degrees, wherein the second incision is spaced inwardly from the first exterior edge and the second exterior edge; and affixing the first film layer to the second film layer along the first exterior edge and the second exterior edge, and a periphery of the first incision and the second incision such that a fluid-filled portion is formed between the first film layer and the second film layer, the fluid-filled portion positioned inwardly from the first exterior edge and the second exterior edge and around the first incision and the second incision.
 18. The method of claim 17 further comprising: forming a third incision through the first film layer and the second film layer, wherein the third incision is spaced inwardly from the first exterior edge and the second exterior edge, and forming a fourth incision through the first film layer and the second film layer, the fourth incision extending from the third incision at an angle that is less than 180 degrees, wherein the fourth incision is spaced inwardly from the first exterior edge and the second exterior edge.
 19. The method of claim 17 further comprising: positioning a first textile layer adjacent to the first film layer; positioning a second textile layer adjacent to the second film layer; and affixing the first textile layer to the second textile layer at one or more of the first incision and the second incision.
 20. The method of claim 17, wherein the first incision and the second incision are linear. 